Use of superconductor type catalysts in the preparation of tertiary butyl alcohol from tertiary butyl hydroperoxide

ABSTRACT

A method for preparing tertiary butyl alcohol wherein a solution of a tertiary butyl hydroperoxide in tertiary butyl alcohol is charged to a hydroperoxide decomposition reaction zone containing a catalytically effective amount of a hydroperoxide decomposition catalyst consisting essentially of a superconductor such as a superconductor consisting essentially of the oxides of strontium, calcium, copper and bismuth and is brought into contact with the superconductor type catalyst in liquid phase with agitation under hydroperoxide decomposition reaction conditions to convert the tertiary butyl hydroperoxide to decomposition products, principally tertiary butyl alcohol.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the catalytic decomposition of tertiary butyl hydroperoxide (TBHP). More particularly, this invention relates to a method for the preparation of tertiary butyl alcohol (TBA) by the catalytic decomposition of tertiary butyl hydroperoxide. Still more particularly, this invention relates to a method wherein a superconductor type catalyst is used to catalyze the substantially selective decomposition of tertiary butyl hydroperoxide to tertiary butyl alcohol.

2. Prior Art

It is known to react isobutane with oxygen, either thermally or catalytically, to form a peroxidation reaction product wherein the principal peroxide that is formed is tertiary butyl hydroperoxide. It is also known to thermally or catalytically decompose the tertiary butyl hydroperoxide to form tertiary butyl alcohol.

In the text entitled "Organic Peroxides" edited by Daniel Swern (Wiley Interscience, a Division of John Wiley & Sons, New York), in Vol. II on page 157 it is stated that the metal-ion-catalyzed decomposition of primary hydroperoxides yields mainly alcohols, aldehydes and carboxylic acids, citing as an example the decomposition of hydroxymethyl hydroperoxide with aqueous ferrous sulfate to provide formaldehyde, formic acid and water.

Quin U.S. Pat. No. 2,854,487 discloses the hydrogenation of hydrocarbon peroxides in the presence of hydrogen and palladium on activated alumina to provide carbinols.

In Massie U.S. Pat. No. 3,775,472 a process is disclosed wherein alkyl substituted aromatic hydrocarbons are oxidized to products such as aromatic alcohols, aldehydes and carboxylic acids in the presence of ruthenium compounds.

Grane U.S. Pat. No. 3,474,151 discloses that tertiary butyl alcohol starts to dehydrate at 450° F. and to decompose at a "rapid rate" at temperatures above 475° F. Grane discovered, however, that residual quantities of hydroperoxide contaminants present in tertiary butyl alcohol could be thermally decomposed by heating the contaminated tertiary butyl alcohol at a temperature of 375° to 475° F. for about 1 to 10 minutes.

Grane et al. U.S. Pat. No. 4,294,999 discloses a process wherein isobutane is oxidized in a pressured reactor in the presence of a solubilized molybdenum catalyst to provide a mixture of tertiary butyl alcohol, tertiary butyl hydroperoxide, methanol, acetone, and other oxygen-containing compounds. The tertiary butyl hydroperoxide is thermally decomposed under pressure at about 280° F. to provide a tertiary butyl alcohol product containing only residual quantities of tertiary butyl hydroperoxide which are then decomposed in accordance with Grane U.S. Pat. No. 3,474,151 by heating the tertiary butyl alcohol at 375° to 475° for about 1 to 10 minutes. Heating tertiary butyl alcohol containing small amounts of peroxides at high temperatures for even short periods of time to remove the peroxides produces undesirable products such as isobutylene.

Grane et al. U.S. Pat. No. 4,296,262 discloses a related process wherein isobutane is reacted with oxygen in a reaction zone for a residence time of about 1 to 10 hours at a temperature of about 240° to about 340° F. and a pressure of about 100 to about 1000 psig. in the presence of a catalytically effective amount of a soluble molybdenum catalyst. A liquid stream comprising tertiary butyl alcohol is recovered from the reaction mixture and fed to a decomposition zone wherein the tertiary butyl hydroperoxide contained therein is decomposed by "hot aging" at 250°-350° F. at a pressure lower than the pressure in the oxidation zone. The tertiary butyl alcohol can be further subjected to a clean-up treatment at 375°-475° F. for 1 to 10 minutes. Worrell et al. in U.S. Pat. No. 4,296,263 disclose a related process wherein the feedstock is a mixture of normal butane with isobutane and wherein the oxidation catalyst is a soluble form of chromium, cobalt, nickel, manganese, molybdenum, or a mixture thereof.

In U.S. Pat. No. 3,505,360, Allison et al. disclose a method wherein an alkenyl hydroperoxide is decomposed in the presence of a catalyst based on a compound of a Group IV-A, V-A or VI-A metal. Taylor et al., in U.S. Pat. No. 4,508,923 disclose the use of a catalyst system comprising ruthenium and chromium for decomposing organic hydroperoxides. The use of a cobalt borate catalyst for the decomposition of hydroperoxides is disclosed in Sanderson et al. U.S. Pat. No. 4,547,598.

Taylor et al. U.S. Pat. No. 4,551,553 is directed to a process for the formation of alcohols such as tertiary butyl alcohol by the catalytic decomposition of an organic hydroperoxide such as tertiary butyl hydroperoxide using a binary catalyst composed of a mixture of a ruthenium compound with a chromium compound. It is stated that the use of the binary catalyst eliminates the need for stabilizing ligands.

Sanderson et al. disclose the use of a variety of catalysts for the decomposition of tertiary butyl hydroperoxide in a series of U.S. patents, including a catalyst composed of unsupported nickel, copper, chromia and iron (U.S. Pat. No. 4,704,482), a catalyst composed of iron, copper, chromia and cobalt (U.S. Pat. No. 4,705,903), a catalyst composed of a base treated hydrogenation catalyst from groups VIB or VIIIB of the Periodic Table (U.S. Pat. No. 4,742,179), a catalyst consisting essentially of nickel, copper, chromium and barium (U.S. Pat. No. 4,873,380), a catalyst composed of a metal phthalocyanine promoted with a rhenium compound (U.S. Pat. No. 4,910,349), a catalyst composed of a base promoted metal phthalocyanine compound (U.S. Pat. No. 4,912,269), a catalyst composed of a soluble ruthenium compound promoted with a bidentate ligand (U.S. Pat. No. 4,912,033), a catalyst composed of a metal porphine such as iron (III) or manganese (III) promoted with an alkyl thiol or an amine, a catalyst composed of an imidazole promoted metal phthalocyanine compound (U.S. Pat. No. 4,912,266), (U.S. Pat. No. 4,922,034), a catalyst composed of a metal phthalocyanine promoted with a thiol and a free radical inhibitor (U.S. Pat. No. 4,922,035), a catalyst composed of a borate promoted metal phthalocyanine (U.S. Pat. No. 4,922,036), or a catalyst composed of a soluble ruthenium compound and an iron compound such as an acetate, a borate, a bromide, a chloride, a 1,3-propanedionate, a 2-ethylhexanoate, an iodide, a nitrate, a 2,4-pentanedionate, a perchlorate or a sulfate (U.S. Pat. No. 5,025,113).

BACKGROUND INFORMATION

When isobutane is reacted with molecular oxygen, the principal products of the reaction are tertiary butyl alcohol and tertiary butyl hydroperoxide. However, minor amounts of other contaminants are also formed.

In addition, a minor amount of water will be formed, which will normally amount to about 0.5 to 1 wt. % of the reactor effluent. The amount of byproduct water that is produced is a function of the severity of the reaction conditions employed and will tend to increase as the severity of the reaction conditions is increased.

A listing of the components present in a representative reaction product, and their nominal boiling points is given in Table A.

                  TABLE A                                                          ______________________________________                                         Component          NBP (°C.)                                            ______________________________________                                         Isobutane          -11.7                                                       Methyl formate     31.8                                                        Acetone            56.3                                                        Isobutylene oxide  60.0                                                        Isobutyraldehyde   64.1                                                        Methanol           64.7                                                        Methyl-t-butyl peroxide                                                                           74.2                                                        Isopropyl alcohol  82.3                                                        Tertiary butyl alcohol                                                                            82.4                                                        Ditertiary butyl peroxide                                                                         111.0                                                       t-butyl-i-pr-peroxide                                                                             124.0                                                       Tertiary butyl formate                                                                            163.8                                                       ______________________________________                                    

The minor by-products are sometimes difficult to remove. For example, tertiary butyl formate has a higher boiling point than ditertiary butyl peroxide but tends to distill overhead, which suggests that it forms a minimum boiling azeotrope with another component or components.

As indicated, tertiary butyl hydroperoxide is useful as a raw material for the manufacture of tertiary butyl alcohol. The tertiary butyl alcohol can be formed by catalytic decomposition of the tertiary butyl hydroperoxide. In the Williams et al. process disclosed in U.S. Pat. No. 3,472,876, an oxygen-containing gas was charged to a reactor containing isobutane and an oxidation catalyst to provide a reaction mixture comprising tertiary butyl alcohol, tertiary butyl hydroperoxide, acetone, and tertiary butyl ether. The reported results in the patent indicate that there was a comparatively low rate of conversion and a comparatively poor selectivity of the reaction to tertiary butyl alcohol.

SUMMARY OF THE INVENTION

A feedstock for the present invention is suitably one obtained by the oxidation of isobutane with molecular oxygen to provide an oxidation reaction product from which a solution of tertiary butyl hydroperoxide in tertiary butyl alcohol can be obtained by distillation. The feedstock for the present invention may comprise tertiary butyl hydroperoxide dissolved in tertiary butyl alcohol which is recovered from the isobutane oxidation reaction product. The feedstock is charged to a catalytic decomposition zone wherein the tertiary butyl hydroperoxide is decomposed in the presence of a superconductor catalyst to provide a decomposition reaction product characterized by a high conversion rate and a high selectivity of tertiary butyl hydroperoxide to tertiary butyl alcohol.

The tertiary butyl alcohol will not be the only decomposition product that is formed. Minor amounts of other oxygen-containing materials such as those listed above will also be formed.

The tertiary butyl alcohol that is recovered from the decomposition reaction mixture will be contaminated with the oxygenated impurities.

DESCRIPTION OF THE PROCESS OF THE PRESENT INVENTION

The starting materials for the process of the present invention are a tertiary butyl hydroperoxide feedstock and a superconductor catalyst.

The Tertiary Butyl Hydroperoxide Feedstock

The feedstock to be used in accordance with the present invention is a solution of tertiary butyl hydroperoxide in tertiary butyl alcohol that preferably contains from about 5 to about 30 wt. % of tertiary butyl hydroperoxide. As indicated, the feedstock is suitably prepared by the oxidation of isobutane to form an oxidation product from which a feedstock of the present invention can be recovered by distillation.

The Catalyst System

The catalyst to be used in accordance with the present invention is a superconductor type hydroperoxide decomposition catalyst of the type disclosed in U.S. Pat. No. 5,047,391, such as a catalyst consisting essentially of the oxides of strontium, calcium, copper and bismuth.

A superconductor catalyst composed of the oxides of strontium, calcium, copper and bismuth may suitably contain from about 0.1 to about 25 wt. % of SrO, from about 10 to about 75 wt. % of CaO, from about 0.1 to about 2.5 wt. % of CuO, and from about 10 to about 75 wt. % of Bi₂ O₃. As an example, the catalyst may contain about 23.25 wt. % of SrO, about 67.25 wt. % of CaO, about 18 wt. % of CuO and about 52.5 wt. % of Bi₂ O₃.

Catalytic Decomposition of Tertiary Butyl Hydroperoxide

The process of the present invention may be conducted batchwise in kettles or by continuously passing the reactants through a tubular reactor.

The catalytic decomposition of the tertiary butyl hydroperoxide is preferably conducted at a temperature within the range of about 20° to about 250° C. and, more preferably, at a temperature within the range of about 40° to about 150° C. The reaction is preferably conducted at autogenous pressure although superatmospheric pressures up to about 1000 psig. may be used, if desired.

Flow rates of the charge solution to the reaction zone should be adjusted in order to provide an appropriate contact time within the reactor. In a batch process, the holding time may suitably be from about 0.5 to about 10 hours, and more preferably about 1 to 3 hours.

In accordance with the most preferred embodiment of the present invention, isobutane is reacted with oxygen in an oxidation zone under oxidation reaction conditions including a temperature of about 135 to about 155° C., a pressure of about 300 to about 800 psig., and a holding time of about 2 to about 6 hours to provide an initial oxidation reaction product comprising unreacted isobutane, tertiary butyl hydroperoxide, tertiary butyl alcohol, and oxygen-containing by-products. The oxidation reaction product is fractionated in any appropriate manner (e.g., by distillation in a distillation zone) to remove the isobutane therefrom for recycle and to provide a solution of tertiary butyl hydroperoxide an tertiary butyl alcohol which will normally contain from about 5 to about 30 wt. % of tertiary butyl hydroperoxide. If the tertiary butyl hydroperoxide concentration is excessive, additional tertiary butyl alcohol may be added.

The solvent solution of tertiary butyl alcohol in organic solvents (e.g., tertiary butyl alcohol solvent solution of tertiary butyl hydroperoxide) is then charged to a catalytic hydroperoxide decomposition zone where it is brought into contact with a system composed of a superconductor type catalyst to substantially selectively convert the tertiary butyl hydroperoxide to tertiary butyl alcohol with high yields and selectivities.

As indicated, the catalytic decomposition of the tertiary butyl hydroperoxide in the catalytic hydroperoxide decomposition reaction zone may suitably be conducted at a temperature within the range of about 20° to about 250° C. (and more preferably from about 40° to about 150° C.) at autogenous pressure or if desired at a superatmospheric pressure up to 1000 psig. for a contact time within the range of about 0.5 to about 10 hours, and more preferably about 1 to 3 hours.

The reaction product from the tertiary butyl hydroperoxide decomposition step may then be fractionated in any suitable manner, such as by extractive distillation to recover the tertiary butyl alcohol.

SPECIFIC EXAMPLES

The invention will be further illustrated by the following specific examples which are given by way of illustration and not as limitations on the scope of this invention.

Catalyst Preparation (6927-22)

The procedure for the preparation of the superconductor catalyst is similar to Example 2 of U.S. Pat. No. 5,047,391.

A mixture of SrO (9.3 g), CaO (2.5 g), CuO (7.2 g), and Bi₂ O₃ (21.0 g) was ground together and then heated at 1000° C. for 3.0 hours. The mixture was cooled to ambient temperature and a dark colored melt obtained. The melt was ground into a fine powder, and used without further treatment.

Procedure

A 20% solution TBHP in TBA and catalyst were charged to an autoclave equipped with glass liner, Magnedrive stirrer, cooling coil, and electric heater. The mixture was heated to the desired temperature for the desired time with vigorous stirring. The mixture was then cooled to ambient temperature, filtered if any solid residue present and analyzed by GC. The results are detailed in the attached tables.

                                      TABLE I                                      __________________________________________________________________________     CATALYTIC CONVERSION OF TERT-BUTYL HYDROPEROXIDE                               TO TERT-BUTYL ALCOHOL                                                                        Notebook Number                                                                6844-10-G                                                                            6906-67                                                                              6906-68                                                                              6906-69                                                                              6906-70                                  __________________________________________________________________________     Catalyst            Sr, Ca, Cu, Bi Superconductor                              Solution (g)        100.0 100.0 100.0 100.0                                    Catalyst (g)        0.20  0.20  0.20  0.20                                     Catalyst (%)        0.2   0.2   0.2   0.2                                      Temperature (°C.)                                                                           80    100   120   140                                      Reaction Time (hr)  4     4     4     4                                        TBHP Conversion (mol. %)                                                                           62.5  98.3  99.9  100.0                                    Selectivity IC4═ (mol. %)                                                                      0.0   0.0   0.0   0.1                                      Sel. Acetone (mol. %)                                                                              8.9   15.8  19.0  38.0                                     Sel. Methanol (mol. %)                                                                             2.1   5.1   7.8   12.2                                     Sel. TBA (mol. %)   86.0  81.1  79.3  62.6                                     Sel. DTBP (mol. %)  5.1   3.1   1.8   -0.6                                     Remarks       H2O Free                                                                             H2O Free                                                                             H2O Free                                                                             H2O Free                                                                             H2O Free                                               Basis Basis Basis Basis Basis                                    Composition                                                                    IC4═      0.000 0.000 0.000 0.001 0.006                                    MEOH/MF       0.020 0.111 0.361 0.551 0.846                                    Acetone       0.037 0.722 1.950 2.367 4.713                                    TBA           79.823                                                                               89.581                                                                               95.092                                                                               95.663                                                                               93.137                                   DTBP          0.145 0.639 0.613 0.420 0.045                                    TBHP          19.090                                                                               7.155 0.318 0.026 0.004                                    __________________________________________________________________________

                                      TABLE II                                     __________________________________________________________________________     CATALYTIC CONVERSION OF TERT-BUTYL HYDROPEROXIDE                               TO TERT-BUTYL ALCOHOL                                                                        Notebook Number                                                                6844-10-G                                                                            6879-1                                                                               6879-2                                                                               6879-3                                                                               6879-4                                   __________________________________________________________________________     Catalyst            Iron  Iron  Iron  Iron                                                         Naph- Naph- Naph- Naph-                                                        thenate                                                                              thenate                                                                              thenate                                                                              thenate                                  Solution (g)        50.0  50.0  50.0  50.0                                     Catalyst (g)        0.10  0.10  0.10  0.10                                     Catalyst (%)        0.2   0.2   0.2   0.2                                      Temperature (°C.)                                                                           80    100   120   140                                      Reaction Time (hr)  4     4     4     4                                        TBHP Conversion (mol. %)                                                                           0.0   3.8   53.4  98.5                                     Selectivity IC4═ (mol. %)                                                                      0.0   0.0   0.0   0.0                                      Sel. Acetone (mol. %)                                                                              0.0   0.0   13.1  26.1                                     Sel. Methanol (mol. %)                                                                             0.0   0.0   6.3   13.2                                     Sel. TBA (mol. %)   0.0   0.0   85.6  74.5                                     Sel. DTBP (mol. %)  0.0   0.0   1.4   -0.7                                     Remarks       H2O Free                                                                             H2O Free                                                                             H2O Free                                                                             H2O Free                                                                             H2O Free                                               Basis Basis Basis Basis Basis                                    Composition                                                                    IC4═      0.000 0.000 0.000 0.000 0.001                                    MEOH/MF       0.020 0.016 0.040 0.247 0.905                                    Acetone       0.037 0.236 0.292 0.896 3.205                                    TBA           79.823                                                                               77.969                                                                               80.161                                                                               88.724                                                                               94.705                                   DTBP          0.145 0.145 0.196 0.257 0.041                                    TBHP          19.090                                                                               20.774                                                                               18.368                                                                               8.905 0.291                                    __________________________________________________________________________

First of all, it is clear that the superconductor type catalyst of this invention is more active than typical peroxide decomposition catalysts such as iron naphthenate.

For example, at 80° C., and a 4.0 hour reaction time, the catalyst of this invention shows a TBHP conversion of 62.5% with a selectivity to TBA of 86.0%. Under the same conditions (80° C., 4.0 hour reaction time), iron naphthenate shows essentially no conversion of TBHP to TBA.

In general, the lower the temperature of conversion of TBHP, the higher the selectivity to TBA. 

Having thus described our invention, what is claimed is:
 1. In a method wherein a solution of a tertiary butyl hydroperoxide charge stock in tertiary butyl alcohol is brought into contact with a catalytically effective amount of a hydroperoxide decomposition catalyst in a hydroperoxide decomposition reaction zone in liquid phase with agitation to convert said tertiary butyl hydroperoxide to decomposition products, principally tertiary butyl alcohol, the improvement which comprises:a) using a superconductor as said hydroperoxide decomposition catalyst, and b) recovering tertiary butyl alcohol from the products of said hydroperoxide decomposition reaction.
 2. A method as in claim 1 wherein the superconductor catalyst is a superconductor consisting essentially of the oxides of strontium, calcium, copper and bismuth.
 3. A method as in claim 2 wherein the catalyst contains from about 0.1 to about 25 wt. % of SrO, from about 10 to about 75 wt. % of CaO, from about 0.1 to about 25 wt. % of CuO, and from about 10 to about 75 wt. % of Bi₂ O₃.
 4. A method as in claim 3 wherein the catalyst contains about 23.25 wt. % of SrO, about 67.25 wt. % of CaO, about 18 wt. % of CuO and about 52.5 wt. % of Bi₂ O₃.
 5. In a method wherein a solution of a tertiary butyl hydroperoxide charge stock in tertiary butyl alcohol that contains from about 5 to about 30 wt. % of tertiary butyl hydroperoxide is brought into contact with a catalytically effective amount of a hydroperoxide decomposition catalyst in a hydroperoxide decomposition reaction zone in liquid phase with agitation under hydroperoxide conversion conditions including a temperature within the range of about 20° to about 250° C. and a pressure of about 0 to about 1,000 psig to convert said tertiary butyl hydroperoxide to decomposition products, principally tertiary butyl alcohol, the improvement which comprises:a) using a superconductor as said hydroperoxide decomposition catalyst and b) recovering tertiary butyl alcohol from the products of said hydroperoxide decomposition reaction.
 6. A method as in claim 5 wherein the temperature is in the range of about 40° to about 150° C., the pressure is about 0 psig and the superconductor catalyst is a superconductor consisting essentially of the oxides of strontium, calcium, copper and bismuth.
 7. A method as in claim 6 wherein the catalyst contains from about 0.1 to about 25 wt. % of SrO, from about 10 to about 75 wt. % of CaO, from about 0.1 to about 25 wt. % of CuO, and from about 10to about 75 wt. % of Bi₂ O₃.
 8. A method as in claim 7 wherein the catalyst contains about 23.25 wt. % of SrO, about 67.25 wt. % of CaO, about 18 wt. % of CuO and about 52.5 wt. % of Bi₂ O₃. 